Modular Angled Bioreactor Panels for Scalable Microalgae Production
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Solution Overview
Problem
Current bioreactors for large-scale microalgae production are costly to construct and operate, lack flexibility, and are not easily scalable, limiting their efficiency and adaptability for optimizing culture conditions such as light exposure.
Innovation Solution
The development of modular, closed-system bioreactors with a container oriented at angles, allowing for adjustable light exposure and aeration, featuring a support structure that enables easy modification of angles for optimal growth conditions, and incorporating gas sparging for mixing and nutrient introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional bioreactors are used for large-scale microalgae production, then production capacity is achieved, but construction and operation costs are high
Solution Approach 1:
The bioreactor system is divided into multiple modular panels that can be independently manufactured and assembled. Each panel contains integrated components (containers, supports, sparging devices) that can be produced separately and then combined to form large-scale systems, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The bioreactor panels are designed as universal modules that can be configured for different production scales and applications. The same basic panel design serves multiple functions: containing culture medium, providing structural support, enabling gas sparging, and facilitating modular expansion, thereby reducing the need for specialized components.
2Productivity
If traditional bioreactors are used for large-scale microalgae production, then production capacity is achieved, but flexibility and scalability are limited
Solution Approach 1:
The system uses segmented modular panels that can be easily added or removed to scale production capacity up or down. This segmentation allows flexible adaptation to changing production requirements without requiring complete system redesign or complex reconfiguration.
Solution Approach 2:
The bioreactor system incorporates adjustable container orientations (0° to 90° angles) that can be dynamically modified to optimize light exposure and growth conditions. This dynamic adjustability enhances the system's adaptability to different operational requirements and environmental conditions.
3Device complexity
If fixed-angle container orientation is used, then structural simplicity is maintained, but ability to optimize light exposure is reduced
Solution Approach 1:
The container orientation within each panel can be adjusted to different angles (0° to 90°) to optimize light exposure conditions. This dynamic positioning capability allows the system to adapt to varying light conditions throughout the day or season while maintaining a relatively simple overall panel structure.
Solution Approach 2:
Different containers within the same panel can be oriented at different angles to create localized optimization zones. This allows specific areas to be tailored for maximum light capture while other areas maintain simpler orientations, balancing structural simplicity with illumination optimization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular bioreactors provide efficient biomass production with reduced costs, energy, and water usage, while allowing for flexible scaling and optimized culture conditions, enhancing growth rates and productivity of microalgae and other cell types.
Implementation Method 1
Gas and/or nutrients are introduced through an opening in such a way as to provide mixing and aeration of a cell culture in the bioreactor
Implementation Method 2
Gas and/or nutrients are introduced through an opening in such a way as to provide mixing and aeration of a cell culture in the bioreactor
Implementation Method 3
the method includes exposing the culture in the bioreactor to a light source (such as sunlight or an artificial light source)
Data Source
AI summary
Disclosed herein are bioreactors that include a container for holding fluid aligned on a vertical axis, wherein at least a portion of the container is oriented at an angle relative to the vertical axis, wherein the angle is from about 0° to 90°. In some embodiments, the container is placed on a support structure with portions of the container oriented at alternating angles. The system is essentially closed except for at least one opening (for example an opening at the bottom edge) that allows for the introduction of gases and/or nutrients. The gas and/or nutrients are introduced in such a way as to provide mixing and aeration of a cell culture in the bioreactor. Also disclosed are methods of culturing cells (such as microalgae, macroalgae, bacteria, fungi, insect cells, plant cells, animal cells, or plant or animal tissue or organs) using a bioreactor described herein.